Beckhoff EP6002-0002 Documentation

Documentation

EP6002-0002

2-channel serial interface (RS232 / RS422 / RS485)

1.0

2019-12-11

Version:

Date:

Table of contents

EP6002-0002 3Version: 1.0

Table of contents

1 Foreword ....................................................................................................................................................5

1.1 Notes on the documentation..............................................................................................................5

1.2 Safety instructions .............................................................................................................................6

1.3 Documentation Issue Status..............................................................................................................7

2 Product overview.......................................................................................................................................8

2.1 Product group: EtherCAT Box Modules ............................................................................................8

2.2 Introduction........................................................................................................................................9

2.3 Technical data .................................................................................................................................10

2.4 Scope of supply ...............................................................................................................................11

2.5 Process image.................................................................................................................................12

2.5.1 Assignment of connectors to process data...................................................................... 13

2.5.2 Control word .................................................................................................................... 14

2.5.3 Status word...................................................................................................................... 14

2.6 Technology ......................................................................................................................................15

3 Mounting and connection.......................................................................................................................16

3.1 Mounting..........................................................................................................................................16

3.1.1 Dimensions ...................................................................................................................... 16

3.1.2 Fixing ............................................................................................................................... 17

3.2 Supply voltages ...............................................................................................................................18

3.2.1 Connectors ...................................................................................................................... 18

3.2.2 Status LEDs..................................................................................................................... 19

3.2.3 Conductor losses ............................................................................................................. 19

3.3 EtherCAT.........................................................................................................................................20

3.3.1 Connectors ...................................................................................................................... 20

3.3.2 Status LEDs..................................................................................................................... 21

3.3.3 Cables.............................................................................................................................. 21

3.4 RS232..............................................................................................................................................22

3.4.1 Connectors ...................................................................................................................... 22

3.4.2 Status LEDs..................................................................................................................... 22

3.5 RS422 / RS485................................................................................................................................23

3.5.1 Connectors ...................................................................................................................... 23

3.5.2 Status LEDs..................................................................................................................... 23

3.6 UL Requirements.............................................................................................................................24

4 Commissioning/Configuration ...............................................................................................................25

4.1 Configuration in TwinCAT................................................................................................................25

4.2 Serial interfaces...............................................................................................................................26

4.2.1 Parameterization of the interface type ............................................................................. 26

4.2.2 Setting the interface parameters...................................................................................... 30

4.2.3 Communication by PLC program..................................................................................... 31

4.2.4 Communication via a virtual COM port ............................................................................ 33

4.3 CoE objects .....................................................................................................................................34

4.3.1 Directory .......................................................................................................................... 34

4.3.2 Object description and parameterization ......................................................................... 35

Table of contents

EP6002-00024 Version: 1.0

4.4 Restoring the delivery state .............................................................................................................57

4.5 Decommissioning ............................................................................................................................58

5 Appendix ..................................................................................................................................................59

5.1 General operating conditions...........................................................................................................59

5.2 EtherCAT Box- / EtherCATPBox - Accessories ............................................................................60

5.3 General note on the introduction of the Beckhoff Identification Code (BIC) ....................................61

5.4 Support and Service ........................................................................................................................63

Foreword

EP6002-0002 5Version: 1.0

1 Foreword

1.1 Notes on the documentation

Intended audience

This description is only intended for the use of trained specialists in control and automation engineering who

are familiar with the applicable national standards.

It is essential that the documentation and the following notes and explanations are followed when installing

and commissioning these components.

It is the duty of the technical personnel to use the documentation published at the respective time of each

installation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all the

requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly under

development.

We reserve the right to revise and change the documentation at any time and without prior announcement.

No claims for the modification of products that have already been supplied may be made on the basis of the

data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff

®

, TwinCAT

®

, EtherCAT

®

, EtherCATG

®

, EtherCATG10

®

, EtherCATP

®

, SafetyoverEtherCAT

®

,

TwinSAFE

®

, XFC

®

, XTS

®

and XPlanar

®

are registered trademarks of and licensed by Beckhoff Automation

GmbH. Other designations used in this publication may be trademarks whose use by third parties for their

own purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and

patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding

applications or registrations in various other countries.

EtherCAT

®

is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,

Germany.

Copyright

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

Foreword

EP6002-00026 Version: 1.0

1.2 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!

Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,

commissioning etc.

Exclusion of liability

All the components are supplied in particular hardware and software configurations appropriate for the

application. Modifications to hardware or software configurations other than those described in the

documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are

familiar with the applicable national standards.

Description of instructions

In this documentation the following instructions are used.

These instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow this safety instruction directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow this safety instruction endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow this safety instruction can lead to injuries to persons.

NOTE

Damage to environment/equipment or data loss

Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Foreword

EP6002-0002 7Version: 1.0

1.3 Documentation Issue Status

Version Modifications

1.0 • First release, adapted from the documentation EP600x V2.1.0

Firmware and hardware versions

This documentation refers to the firmware and hardware version that was applicable at the time the

documentation was written.

The module features are continuously improved and developed further. Modules having earlier production

statuses cannot have the same properties as modules with the latest status. However, existing properties

are retained and are not changed, so that older modules can always be replaced with new ones.

The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on

the side of the EtherCAT Box.

Syntax of the batch number (D-number)

D: WW YY FF HH

WW - week of production (calendar week)

YY - year of production

FF - firmware version

HH - hardware version

Example with D no. 29 10 02 01:

29 - week of production 29

10 - year of production 2010

02 - firmware version 02

01 - hardware version 01

Beckhoff Identification Code (BIC)

The Beckhoff Identification Code contains additional information about the delivery state of the module:

General note on the introduction of the Beckhoff Identification Code (BIC) [}61].

Product overview

EP6002-00028 Version: 1.0

2 Product overview

2.1 Product group: EtherCAT Box Modules

EtherCAT Box modules are I/O modules for industrial controllers.

They comply with protection class IP67 and are intended for use outside the control cabinet in wet, dirty or

dusty industrial environments.

EtherCAT Box modules communicate with the controller via the EtherCAT fieldbus. They each have two

connections for EtherCAT communication and for the power supply:

• Feed

• Downstream connection

This enables the cabling of EtherCAT Box modules in a line structure:

Power

EtherCAT

...

Fig.1: EtherCAT Box modules: Example of cabling in a line structure

Product overview

EP6002-0002 9Version: 1.0

2.2 Introduction

Fig.2: EP6002-0002

EP6002-0002 | 2-channel serial interface, RS232, RS422/RS485

The EP6002 serial interface module allows the connection of devices with an RS232 or RS422/RS485

interface. The module transmits the data in a fully transparent manner to the higher-level automation device.

The data is transferred via the fieldbus using a simple handshake protocol. This does not have any effect on

the protocol of the serial interface. The active serial communication channel functions independently of the

higher-level bus system in full duplex mode at up to 115,200 baud, while a 864 byte receive buffer and a 128

byte send buffer are available.

The connector assignment depends on the interface. For each channel, RS232 or RS422/RS485 can be

selected.

In conjunction with the TwinCAT Virtual Serial COM Driver (see TwinCAT Supplements – Communication)

the EP6002 can be used as a normal Windows COM interface.

Product overview

EP6002-000210 Version: 1.0

2.3 Technical data

All values are typical values at 25°C, unless otherwise stated.

Technical data EP6002-0002

Fieldbus

Fieldbus EtherCAT

Connection 2x M8 socket, green

Electrical isolation 500V (fieldbus/ IO)

Supply voltages

Connection Feed: 1 x M8 plug, 4-pin, black

Downstream connection: 1 x M8 socket, 4-pin, black

Control voltage U

S

Nominal voltage 24V

DC

(-15%/ +20%)

Sum current max. 4A

1)

Consumers • Module electronics: 130mA

• Remote communication stations (e.g. barcode scanner)

Peripheral voltage U

P

Nominal voltage 24V

DC

(-15%/ +20%)

Sum current max. 4A

1)

Consumers -

Serial interface

Number of channels 2

Interface type Individually parameterizable for each channel:

• RS232

• RS422

• RS485

Connection 1x M12 socket per channel

Remote station supply voltage

2)

5V

DC

, isolated potential

max. 20mA

Cable length RS232: max. 15m

RS422/RS485: max. 1,000m

Data transfer rate Parameterizable:

300 .. 115,200baud (bit/s)

Data format Parameterizable:

8N1, 7E1, 7O1, 8N1, 8E1, 8O1, 7E2, 7O2, 8N2, 8E2, 8O2

Receive buffer 864bytes

Transmit buffer 128bytes

Bit distortion <3%

1)

Sum current of consumers and power transmission. This value corresponds to the

current carrying capacity of the connections for the supply voltages.

2)

Supply voltage available at the connections of the serial interface.

Product overview

EP6002-0002 11Version: 1.0

Technical data EP6002-0002

Environmental conditions

Ambient temperature

during operation

-25 .. +60°C

-25 .. +55°C according to cURus

Ambient temperature

during storage

-40.. +85°C

Vibration / shock resistance conforms to EN 60068-2-6 / EN 60068-2-27

EMC immunity / emission conforms to EN 61000-6-2 / EN 61000-6-4

Protection class IP65, IP66, IP67 conforms to EN 60529

Mechanics

Weight approx. 165g

Installation position variable

Approvals and conformity

Approvals CE, cURus

2.4 Scope of supply

Make sure that the following components are included in the scope of delivery:

• 1x EtherCAT Box EP6002-0002

• 2x protective cap for EtherCAT socket, M8, green (pre-assembled)

• 1x protective cap for supply voltage input, M8, transparent (pre-assembled)

• 1x protective cap for supply voltage output, M8, black (pre-assembled)

• 10x labels, blank (1 strip of 10)

Pre-assembled protective caps do not ensure IP67 protection

Protective caps are pre-assembled at the factory to protect connectors during transport. They may

not be tight enough to ensure IP67 protection.

Ensure that the protective caps are correctly seated to ensure IP67 protection.

Product overview

EP6002-000212 Version: 1.0

2.5 Process image

COM TxPDO-Map Inputs

The following figure shows an example of the process data object for serial channel 1. The process data

object for channel 2 is structured in exactly the same way.

Status

Status word [}14] for receive data.

Data In [n]

The input variables "Data In 0" .. "Data In 22" each

contain one byte of receive data (USINT).

"Data In 0" contains the first-received byte.

Product overview

EP6002-0002 13Version: 1.0

COM RxPDO-Map Outputs

The following figure shows an example of the process data object for serial channel 1. The process data

object for channel 2 is structured in exactly the same way.

Ctrl

Control word [}14] for transmit data.

Data Out [n]

The output variables "Data Out 0" .. "Data Out 22"

can each be filled with one byte of send data.

The content of "Data Out 0" is transmitted first.

2.5.1 Assignment of connectors to process data

Connector Chan-

nel

receive data send data

X01

X02

1

COM TxPDO-Map Inputs Channel 1 COM RxPDO-Map Outputs Channel 1

X03

X04

2

COM TxPDO-Map Inputs Channel 2 COM RxPDO-Map Outputs Channel 2

Product overview

EP6002-000214 Version: 1.0

2.5.2 Control word

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Name OL7 OL6 OL5 OL4 OL3 OL2 OL1 OL0 - - - - SC IR RA TR

Bit no. Name Description

15.. 8 OL7.. OL0

(OutLength)

1

dec

.. 22

dec

Number of output bytes available for transfer from the controller to the box.

7..4 reserved

3 SC

(SendContinuous)

rise Continuous sending of data from the FIFO.

The send buffer is filled (up to 128 bytes) by the controller. The buffer content is sent

with rising edge of bit SC. Once the data has been transferred, this is acknowledged

by the box to the controller by setting the SW.2 bit. SW.2 is cancelled with CW.3.

2 IR

(InitRequest)

1

bin

The controller requests the box to initialize. The send and receive functions are

blocked, the FIFO pointers are reset, and the interface is initialized with the values of

the responsible objects (baud rate 4073, data frame 4074, feature bits 4075). The

execution of the initialization is acknowledged by the box with the SW.2 (IA) bit.

0

bin

The controller once again requests the box to prepare for serial data exchange.

1 RA

(ReceiveAccepted)

toggle The controller acknowledges receipt of data by changing the state of this bit. Only

then can new data be transferred from the box to the controller.

0 TR

(TransmitRequest)

toggle Via a change of state of this bit the controller notifies the box that the DataOut bytes

contain the number of bytes indicated via the OL bits. The box acknowledges receipt

of the data in the status byte by changing the state of the SW.0 (TA) bit. Only then

can new data be transferred from the controller to the box.

2.5.3 Status word

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Name IL7 IL6 IL5 IL4 IL3 IL2 IL1 IL0 - OVERRUN

ERR

FRAMING

ERR

PARITY

ERR

BUF_F IA RR TA

Key

Bit no. Name Description

15...8 IL7... IL0

(InLength)

1

dec

.. 22

dec

Number of input bytes available for transfer from the box to the controller.

7 reserved

6 OVERRUN ERR 0 .. 1 An overrun error has occurred. The data concerned is not loaded to the receive

FIFO of the box and is lost.

5 FRAMING ERR 0 .. 1 A framing error has occurred. The data concerned is not loaded to the receive FIFO

of the box and is lost.

4 PARITY ERR 0 .. 1 A parity error has occurred. The data concerned is not loaded to the receive FIFO of

the box and is lost

3 BUF_F 1 The receive FIFO is full. All further incoming data will be lost!

2 IA

(InitAccepted bit)

1 The initialization has been executed by the box.

0 The box is ready again for serial data exchange.

1 RR

(ReceiveRequest)

toggle Via a change of state of this bit the box notifies the controller that the DataIn bytes

contain the number of bytes indicated via the IL bits. The controller has to acknowl-

edge receipt of the data in the control byte via a change of state of bit CW.1 (RA).

Only then can new data be transferred from the box to the controller.

0 TA

(TransmitAccepted)

toggle The box acknowledges the receipt of data by changing the state of this bit. Only then

can new data be transferred from the controller to the box.

Product overview

EP6002-0002 15Version: 1.0

2.6 Technology

Fig.3: Level of RS232, RS422, RS485 interfaces

Data transfer rate

The process image contains 22bytes of user data. It is possible to transmit or receive these 22bytes every

second PLC cycle at the most:

• The data is transferred from the box to the controller in the first PLC cycle.

• In the second PLC cycle, the controller must acknowledge that it has accepted the data.

Therefore, if the cycle time is 10ms, 50times 22bytes can be transmitted per second.

If the data format is set to 8N1, each transmitted byte is made up of a start bit, eight data bits and a stop bit.

This is equivalent to 10bits per byte of user data.

With the above-mentioned settings, a continuous data transfer rate of:

• 50[1/s] x 22[bytes] x 10[bits] = 11000 baud (bit/s)

can be achieved.

The next lower standard data transfer rate is 9600baud. Accordingly, continuous transfer at a maximum

baud rate of 9600 can be secured with a cycle time of 10ms.

If only low quantities of data are transmitted or received sporadically (e.g. barcode scanner), the baud rate

can also be set higher, or the cycle time can be enlarged.

If the controller cannot collect the data quickly enough from the box, the data will be stored intermediately in

the internal buffer of the box. The buffer for received data has a size of 864bytes. If this is exhausted, all

further data will be lost.

A buffer is also available for the transmit data. With a baud rate of 300 and a data format of 8N1, the box can

only transmit 30bytes per second. However, if more than these 30bytes per second are received, a

128bytes transmit buffer will be written to first in this case also. Once this is full, all further data will be lost.

Mounting and connection

EP6002-000216 Version: 1.0

3 Mounting and connection

3.1 Mounting

3.1.1 Dimensions

119

126

23

30

26.5

13.5

Ø 3.5

Fig.4: Dimensions

All dimensions are given in millimeters.

Housing features

Housing material PA6 (polyamide)

Sealing compound polyurethane

Mounting two fastening holes Ø3.5mm for M3

Metal parts brass, nickel-plated

Contacts CuZn, gold-plated

Power feed through max. 4A

Installation position variable

Protection class IP65, IP66, IP67 (conforms to EN60529) when screwed together

Dimensions (HxWxD) approx. 126 x 30 x 26.5mm (without connectors)

Mounting and connection

EP6002-0002 17Version: 1.0

3.1.2 Fixing

NOTE

Dirt during assembly

Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and

connectors are connected.

• Protect the plug connectors against dirt during the assembly.

Mount the module with two M3 screws on the fastening holes in the corners of the module. The fastening

holes have no thread.

Mounting and connection

EP6002-000218 Version: 1.0

3.2 Supply voltages

The EtherCAT Box is supplied with two supply voltages. The supply voltages are electrically isolated in the

EtherCAT Box.

• Control voltage U

S

• Peripheral voltage U

P

Redirection of the supply voltages

The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply

voltages U

S

and U

P

can thus easily be transferred from EtherCATBox to EtherCATBox.

NOTE

Pay attention to the maximum permissible current!

Pay attention also for the redirection of the supply voltages U

S

and U

P

, the maximum permissible current for

M8 connectors of 4A must not be exceeded!

3.2.1 Connectors

NOTE

Risk of confusion: supply voltages and EtherCAT

Defect possible through incorrect insertion.

• Observe the color coding of the connectors:

black: Supply voltages

green: EtherCAT

Fig.5: Connectors for supply voltages

Plug

Feed-in

Socket

Forwarding

3 1

24

3 1

24

Fig.6: M8 connector

Contact Function Description Core color

1)

1 U

S

Control voltage Brown

2 U

P

Peripheral voltage White

3 GND

S

GND to U

S

Blue

4 GND

P

GND to U

P

Black

1)

The core colors apply to cables of the type: Beckhoff ZK2020-xxxx-xxxx

Mounting and connection

EP6002-0002 19Version: 1.0

3.2.2 Status LEDs

Fig.7: Status LEDs for the power supply

LED Display Meaning

U

S

(control voltage) off Supply voltage, U

S

, is not present

green illuminated Supply voltage, U

S

, is present

U

P

(peripheral voltage) off Supply voltage, U

P

, is not present

green illuminated Supply voltage, U

P

, is present

3.2.3 Conductor losses

Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being

so high that the supply voltage at the box lies below the minimum nominal voltage.

Variations in the voltage of the power supply unit must also be taken into account.

Voltage drop on the supply line

Vert. Faktor: 0,45 cm / V

5 10 15 20

2

4

6

8

10

250

0

12

30

Vert. Faktor: 0,45 cm / V

Voltage drop (V)

Cable length (m)

35

0,25 mm²

0,34 mm²

0,5 mm²

0,75 mm²

I = 2 A

Vert. Faktor: 0,45 cm / V

5 10 15 20

2

4

6

8

10

250

0

12

30

Vert. Faktor: 0,45 cm / V

Voltage drop (V)

Cable length (m)

35

0,25 mm²

0,34 mm²

0,5 mm²

0,75 mm²

I = 4 A

Mounting and connection

EP6002-000220 Version: 1.0

3.3 EtherCAT

3.3.1 Connectors

EtherCAT Box Modules have two green M8 sockets for the incoming and downstream EtherCAT

connections.

Fig.8: EtherCAT connector

Connection

3 1

24

Fig.9: M8 socket

EtherCAT M8

connector

Core colors

Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,

ZK1090-6292,

ZK1090-3xxx-xxxx

ZB9031 and old versions of

ZB9030, ZB9032, ZK1090-3xxx-

xxxx

TIA-568B

Tx + 1 yellow

1)

orange/white white/orange

Tx - 4 orange

1)

orange orange

Rx + 2 white

1)

blue/white white/green

Rx - 3 blue

1)

blue green

Shield Housing Shield Shield Shield

1)

Core colors according to EN61918

Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx

For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have

been changed to the EN61918 core colors: yellow, orange, white, blue. So there are different color

codes in circulation. The electrical properties of the cables have been retained when the core colors

were changed.

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